Box-in-box package

ABSTRACT

A box-in-box package includes a rigid outer box made of a foil lined paperboard having a hinged lid configured to provide access to an inner volume of the outer box, a rigid inner box made of a foil lined paperboard having a front wall, a back wall, a top wall, a bottom wall and side walls, and a single opening extending across the top wall and part way down the front wall, the opening configured to provide access to consumer goods in an inner volume of the inner box. The opening in the inner box is a cut-out in the foil lined paperboard. The package can provide an improved barrier to loss of flavor characteristics, a simplified opening arrangement which eliminates a re-sealable pull tab over the opening, better physical protection of product contained in the package, a unique method of opening and closing the package, and a less expensive manufacturing process by eliminating package materials and processing steps to assemble the package with tobacco products such as cigarettes therein.

FIELD

The present disclosure relates to a package for consumer goods andparticularly to a package for smoking article.

BACKGROUND

Numerous approaches have been made for packaging consumer goods. In thecase of cigarettes, for example, packages are designed to preserve theflavor and freshness of the consumer goods and also protect the goodsfrom contamination. Known packages employ outer containers having ahinged lid providing access to an inner container with an opening foraccessing the consumer goods. The outer containers are generally formedof a rigid paperboard, cardboard, or other suitable material. The innercontainer is generally formed of a material or combination of materialshaving substantially less rigidity than the outer container. Forexample, the inner container is known to be formed of paperboard,packing material, paper, and/or aluminium. In known designs, a labelwith a tacky substance for sealing and re-sealing can be used to coverthe opening of the inner container.

SUMMARY

In one example, a box-in-box package comprises a rigid outer box made ofa foil lined paperboard having a hinged lid configured to provide accessto an inner volume of the outer box; a rigid inner box made of a foillined paperboard having a front wall, a back wall, a top wall, a bottomwall and side walls, a single opening extending across the top wall andpart way down the front wall, the opening configured to provide accessto consumer goods in an inner volume of the inner box; the opening inthe inner box comprising a die-cut opening in the foil lined paperboard.

Some example embodiments described herein are directed to a box-in-boxpackage wherein the foil lined paperboard includes a foil layer betweena paper layer and a paperboard layer, an outer surface of the paperlayer adhered to an inner surface of the foil layer by a first adhesivelayer and an inner surface of the paperboard layer adhered to an outersurface of the foil layer a second adhesive layer and further comprisinga polypropylene layer on an outer surface the paperboard layer, whereinthe polypropylene layer comprises a polypropylene film and furthercomprising a polyester layer on an outer surface of the paperboardlayer, wherein the polyester layer comprises a metallized polyestermaterial, wherein the paperboard layer comprises solid bleached sulfate(SBS) board stock, wherein the first adhesive layer comprises sodiumsilicate, wherein consumer goods are contained in the inner box and thepaper layer of the inner box is in direct contact with consumer goodswithin the inner box.

In some example embodiments, the inner box comprises a front panel, atop panel, a back panel, and a bottom panel, wherein the inner boxfurther comprises side panels, wherein the front panel includes a topfront panel and a bottom front panel, wherein the inner box containscigarettes in direct contact with the paper layer of the inner box andthe paper layer of the outer box, wherein the inner box includes a topfront panel separated from a top panel by a first transverse fold line,a back panel separated from the top panel by a second transverse foldline, a bottom panel separated from the back panel by a third transversefold line, and a bottom front panel separated from the bottom panel by afourth transverse fold line, wherein the inner box includes a first sidepanel and a second side panel, and wherein the first side panel isseparated from the back panel by a first longitudinal fold line, and thesecond side panel is separated from the back panel by a secondlongitudinal fold line.

In some example embodiments, a box blank is configured to form an outerbox of the box-in-box package, wherein the box blank is made of foillined paperboard, the foil lined paperboard including a paper layer, afoil layer and a paperboard layer, an outer surface of the paper layeradhered to an inner surface of the foil layer and an inner surface ofthe paperboard layer adhered to an outer surface of the foil layer, theinner surface of the foil layer adhered to the outer surface of thepaper layer by a first adhesive layer and the inner surface of thepaperboard layer adhered to the outer surface of the foil layer by asecond adhesive layer. The box blank can further include a polypropylenelayer on an outer surface of the paperboard layer or a polyester layeron an outer surface of the paperboard layer. The paperboard layer cancomprise solid bleached sulfate (SBS) board stock, wherein the secondlayer further comprises sodium silicate between the foil layer and thepaper layer. The box blank can include fold lines forming panels of abody portion and a lid portion, the body portion including a frontpanel, a bottom panel, a back panel, side panels and dust flaps, and thelid portion including a front panel, top panel, back panel, side panelsand dust flaps.

In a further example embodiment, the foil lined paperboard of the outerbox and inner box comprises a first layer comprising paperboard, asecond layer comprising a paper layer and a foil layer, and an adhesivelayer adhering the first layer to the second layer, wherein the foillayer is between the paperboard and the paper layer.

BRIEF DESCRIPTION OF THE DRAWING FIGURES

The scope of the present disclosure is best understood from thefollowing detailed description of embodiments when read in conjunctionwith the accompanying drawings.

FIG. 1 illustrates a box-in-box package wherein the hinged lid of anouter rigid box is open and access to consumer products in an innerrigid box can be obtained through a cut-out in the upper portion of theinner box.

FIG. 2 illustrates a planar view of an outer box blank of the containerin accordance with an embodiment of the present disclosure.

FIG. 3 illustrates a planar view of an inner box blank of the containerin accordance with an embodiment of the present disclosure.

FIGS. 4a and 4b is a flow chart of a process for assembling thecontainer in accordance with an embodiment of the present disclosure.

FIG. 5 illustrates a sequence of assembly states of the containeraccording to the assembly process of FIGS. 4a and 4 b.

FIG. 6 shows a percentage of the inner box within the outer box.

DETAILED DESCRIPTION

Reference will now be made in detail to the various embodiments, one ormore examples of which are illustrated in each figure. Each example isprovided by way of explanation and is not meant as a limitation. Forexample, features and/or method steps illustrated or described as partof one embodiment and/or method can be used on or in conjunction withother embodiments and/or method steps to yield yet further embodimentsor methods. It is intended that the present disclosure includes suchmodifications and variations.

Embodiments of the present disclosure are directed to a box blank usefulfor forming a container for consumer goods having rigid inner and outerboxes. The outer box has a hinged lid that opens and closes to allowaccess the inner box. The inner box has a die-cut opening for accessingthe consumer goods. The package of the present disclosure can provide amore durable package by protecting the product from physical damagewhile the product is in use and a less expensive packaging solution asfewer pieces of equipment are needed to make the package. Moreover, thepackage assembly can be performed faster and with fewer materialcomponents compare to known re-sealable packaging designs.

A box-in-box package includes a rigid outer box made of a foil linedpaperboard having a hinged lid configured to provide access to an innervolume of the outer box, a rigid inner box made of a foil linedpaperboard having a front wall, a back wall, a top wall, a bottom walland side walls, and a die-cut opening extending across the top wall andpart way down the front wall, the opening configured to provide accessto consumer goods in an inner volume of the inner box. The package canprovide an improved barrier to loss of flavor characteristics, asimplified opening arrangement which eliminates a re-sealable pull tabover the opening, better physical protection of product contained in thepackage, a unique method of opening and closing the package, and a lessexpensive manufacturing process by eliminating package materials andprocessing steps to assemble the package with tobacco products such ascigarettes therein.

FIG. 1 illustrates a layout of a container for consumer goods inaccordance with an embodiment of the present disclosure. As shown inFIG. 1, the container 100 includes a rigid outer box 102 having a hingedtop 104 configured to provide access to a rigid inner box 106 and havinga body 105 within which the inner box 106 is deposited. The inner box106 has a die-cut opening 110 configured to provide access to consumergoods 112 stored or contained within an inner volume 109. The inner box106 is of sufficient size to slidably and snugly fit within an innervolume 108 of the outer box 102. The inner box 106 can be securely heldwithin the outer box 102 via contact friction between the surfaces ofthe inner box 106 and outer box 102. The opening 110 in the inner box106 is a cut-out forming a through hole in one or more panels of theblank which forms the inner box 106. The inner box 106 does not includea re-sealable label (pull tab or cover) over the opening 110. The innerbox 106 can contain unwrapped consumer products such as a group ofsmoking articles and thus provide ready access to consumer itemstherein. In the case of smoking articles, since the smoking articles arenot enclosed in bundle wrap, the consumer can have access to the itemsupon opening the outer box without the need to remove any bundle wrap ofre-sealable pull-tab over the opening. The inner box can provide otheradvantages such as an improved barrier for the product's flavourcharacteristics, simplified consumer opening process by eliminating are-sealable label, more durable package, and/or packaging which can beassembled with fewer pieces of equipment.

The inner box 106 and the outer box 102 are made of foil linedpaperboard including a paper layer, a foil layer and a paperboard layer.To provide rigidity to the inner and out boxes, the paperboard layerpreferably has a thickness of at least 0.010 inch, e.g., 10 or 12 pointpaperboard. The paperboard layer can be formed of solid bleached sulfate(SBS) paperboard such as Promina SBS C1S Paperboard. The paperboard canbe embossed with a design, lettering, pattern, and/or symbol as desired.The paperboard can include an ink, varnish, metallization, or othersuitable material for product identification. When the container 100 isfully assembled, the outer box 102 can be wrapped with a covering layersuch as a polypropylene film with or without a tear tape that allows fortearing open the polypropylene film.

The paper layer of the foil lined paperboard can be thin paper of thetype suitable for wrapping a bundle of cigarettes for example, the paperlayer can be 10 pound or 32 pound paper. The foil layer can be a thinsheet of metal foil such as aluminium having a thickness of at least0.003 inch. For example, the foil layer can be 0.0035 inch thickaluminium foil. Because the paper layer of the foil lined paperboard isan inner layer in direct contact with the consumer goods inside theinner box, it is not necessary to wrap the consumer goods in bundlewrap. The paperboard layer and the foil layer can be adhered to eachother via an adhesive, such as a polyvinyl alcohol (PVA) based adhesive,cold glue, hot melt glue, or other suitable material.

In accordance with another embodiment, the foil lined paperboard caninclude a further layer formed on an outer surface of the paperboardlayer. For example, the further layer can include a polypropylene filmor a metallized polyester (MET) material such that the layer structureof the inner box 106 includes bundle wrap/board/film or bundlewrap/board/MET, and more particularly the layer structure includespaper/foil/board/film or paper/foil/board/MET.

The box-in-box package does not include a re-sealable pull tab attachedto the outer box or to the inner box. Instead, the opening in the innerbox is a cut-out in the foil lined paperboard which allows ready accessto consumer products in the inner box when the hinged lid is opened. Thecut-out thus eliminates any need for a pull tab and simplifies themanufacturing process by eliminating the material of the pull tab alongwith the specialized equipment and manufacturing steps needed toconstruct a package with re-sealable pull tab.

FIG. 2 illustrates a planar view of an outer box blank of the containerin accordance with an embodiment of the present disclosure. As shown inFIG. 2, the blank 500 for forming outer box 102 includes a top panel502, a bottom panel 504, a top front panel 506, a bottom front panel508, a bottom back panel 510, and a top back panel 512. The top panel502 includes a front flap 513. The outer box blank is made of foil linedpaperboard wherein a layer of paperboard is adhered to a foil layerwhich is adhered to a paper layer. The top panel 502 and the bottompanel 504 include left and right dust flaps. The top panel 502 includesa left dust flap 514 and a right dust flap 516, and the bottom panel 504includes a left dust flap 518 and a right dust flap 520. An uppersection 562 of the outer box blank 500 includes the top panel 502, thetop back panel 512, and the top front panel 508 and their associatedside and dust flaps are configured to form the hinged top 104 of theassembled outer box 102 when folded. A lower section 564 of the outerbox blank 500 includes the bottom panel 504, the bottom front panel 506,the bottom back panel 510 and their associated side and dust flapsdiscussed below are configured to form the body 105 of the assembledouter box 102 when folded.

The top back panel 512, the bottom front panel 508, and the bottom backpanel 510 include left and right flaps. For example, the top front panel506 includes a left side flap 522 and a right side flap 524; the topback panel 512 includes a left side flap 526 and a right side flap 528;the bottom front panel 508 includes a left side flap 530 and a rightside flap 532; and the bottom back panel 510 includes a left side flap534 and a right side flap 536.

Each panel of the outer box 102 and the associated left and right flapsare separated from an adjacent panel and its associated left and rightflaps by a transverse fold line. The front flap 513 and the top frontpanel 506 are separated by transverse fold line 539. The top front panel506, the left side flap 522, and the right side flap 524 are separatedfrom the top panel 502, the left dust flap 514, and the right dust flap516, respectively, by transverse fold line 538. The top panel 502, theleft dust flap 514, and the right dust flap 516 are separated from thetop back panel 512, the left side flap 526, and the right side flap 528,respectively, by transverse fold line 540. The top back panel 512, theleft side flap 526, and the right side flap 528 are separated from thebottom back panel 510, the left side flap 534, and the right side flap536, respectively, by transverse fold line 542. The bottom back panel510, the left side flap 534, and the right side flap 536 are separatedfrom the bottom panel 504, the left dust flap 518 and the right dustflap 520, respectively, by transverse fold line 544. The bottom panel504, the left dust flap 518, and the right dust flap 520 are separatedfrom the bottom front panel 508, the left side flap 530, and the rightside flap 532, respectively, by transverse fold line 546.

Each side flap and dust flap of the outer box 102 is separated from theassociated and adjacent panel by a longitudinal fold line. The top frontpanel 506 is separated from the left and right side flaps 522, 524 bylongitudinal fold lines 548. The right side flap 524 has a pre-cut edge525 that extends at an angle of approximately −45° from the transversefold line 539. The left side flap 522 has a pre-cut edge 523 thatextends at an angle of approximately −135° from the transverse fold line539. The top panel 502 is separated from the left and right dust flaps514, 516 by longitudinal fold lines 550. The top back panel 512 isseparated from the left and right side flaps 526, 528 by longitudinalfold lines 552. The left side flap 526 has a pre-cut edge 527 thatextends at an angle of approximately −50° from the transverse fold line542. The right side flap 528 of top back panel 512 has a pre-cut edge529 that extends at an angle approximately −140° from the transversefold line 542. The bottom back panel 510 is separated from the left andright side flaps 534, 536 by longitudinal fold lines 554. The left sideflap 534 has a pre-cut edge 535 that extends at an angle ofapproximately −45° from the transverse fold line 542. The right sideflap 536 of the bottom back panel 510 has a pre-cut edge 537 thatextends at an angle of approximately −135° from the transverse fold line542. The bottom panel 504 is separated from the left and right dustflaps 518, 520 by longitudinal fold lines 556. The bottom front panel508 is separated from the left and right side flaps 530, 532 bylongitudinal fold lines 558. The left side flap 530 and the right sideflap 532 extend past an edge 560 of the bottom front panel 508. The leftside flap 530 has a pre-cut edge 531 that extends at approximately −45°,and in an embodiment −39°, from the bottom edge 560 of the bottom frontpanel 508. The right side flap 532 a pre-cut an edge 533 that extends atapproximately −135°, and in an embodiment −129°, from the edge 560 ofthe front panel 508.

The pre-cut angle of the flaps associated with the bottom front panel508 and bottom back panel 510 are complementary to the pre-cut angle ofthe flaps associated with the top front panel 506 and the top back panel512 so that a side surface of the hinged top of the outer box mates witha side surface of a body of the outer box when the outer box is in aclosed state.

The outer box 102 has dimensions suitable for providing a snug fit forthe inner box 106 when disposed within the outer box 102. The outer box102 has a width W_(OB) that is common to each of the top panel 502,bottom panel 504, top front panel 506, bottom front panel 508, bottomback panel 510, and top back panel 512. The bottom back panel 510 has alength L_(OB-BBP) that is substantially longer than the length of thetop back panel (L_(OB-TBP)) 512. The sum of L_(OB-BBP) and L_(OB-TBP) isapproximately equal to the length of a cigarette pack, e.g., the lengthof the inner box 106. The length of the bottom front panel (L_(OB-BFP))508 is substantially longer than the length of the top front panel(L_(OB-TFP)) 506. The sum of L_(OB-BFP) and L_(OB-TFP) is substantiallyequal to the sum of L_(OB-BBP) and L_(OB-TBP). According to anembodiment L_(OB-BBP)=75.10 mm, L_(OB-TBP)=11.40 mm, L_(OB-BFP)=55.5 mm,and L_(OB-TFP)=31.0 mm. The depth or thickness of the outer box 102 isequal to the width (W_(OB-FLP)) of the side and dust flaps and thelength (e.g., shortest edge) of the top panel (L_(OB-TP)) 502 and bottompanel (L_(OB-BP)) 504. According to an embodimentL_(OB-TP)=L_(OB-BP)=W_(OB-FLP)=21.9 mm

FIG. 3 illustrates a planar view of a blank for forming an inner box 106of the container in accordance with an embodiment of the presentdisclosure. As shown in FIG. 3, the blank 600 for inner box 106 includesa top panel 602, a bottom panel 604, a top front panel 606, a bottomfront panel 608, and a back panel 610. The opening 110 of the inner boxextends across the top front panel 606 and the top panel 602. The innerbox blank is made of foil lined paperboard wherein a layer of paperboardis adhered to a foil layer and the foil layer is adhered to a paperlayer which establishes the product side surface of the assembled innerbox 106.

Each panel is separated from an adjacent panel by a transverse foldline. The top front panel 606 is separated from the top panel 602 by atransverse fold line 612. The top panel 602 is separated from the backpanel 610 by a transverse fold line 614. The back panel 610 is separatedfrom the bottom panel 604 by a transverse fold line 616. The bottompanel 604 and the bottom front panel 608 are separated by transversefold line 618.

Each panel includes associated side flaps. The top front panel 606includes a left side flap 620 and a right side flap 622. The left sideflap 620 has a pre-cut edge 621 that extends at an angle ofapproximately 45° from the transverse fold line 612. The right side flap622 has a pre-cut edge 623 that extends at an angle of approximately135° from the transverse fold line 612. The top panel 602 includes aleft side flap 624 and a right side flap 626. The left side flap 624 hasa pre-cut edge 625 that extends at an angle of approximately 45° fromthe transverse fold line 614. The right side flap 626 has a pre-cut edge627 that extends at an angle of approximately 135° from the transversefold line 614. The back panel 610 includes left side flap 628 and aright side flap 630. The front panel 608 includes a left side flap 632and a right side flap 634.

The bottom panel 604 includes a left dust flap 636 and a right dust flap638.

The inner box 106 has dimensions suitable for storing a desired number(e.g., count) of consumer goods, which according to an embodiment arecigarette articles. The inner box 106 has a width W_(IB) that equals thewidth of each of the top panel 602, bottom panel 604, top front panel606, bottom front panel 608 and back panel 610. The back panel 610 has aheight or length (L_(IB-BKP)) sufficient for enclosing the consumergoods. The sum of the lengths of the top front panel 606 (L_(IB-TFP))and the bottom front panel (L_(IB-BFP)) 608 is equivalent to L_(IB-BKP).According to an embodiment of the present disclosure, L_(IB-BKP)=83.6mm, L_(IB-TFP)=27.2 mm, and L_(IB-BFP)=43.39 mm. The depth or thicknessof the inner box 106 is established by the width W_(IB-FLP) shared byeach of the side and dust flaps and the length (e.g., shortest edge) ofthe top panel (L_(IB-TP)) 602 and bottom panel (L_(IB-BP)) 604.According to an embodiment, L_(IB-TP)=L_(IB-BP)=W_(IB-FLP)=20.55 mm.

According to embodiments of the present disclosure, a sum of lengths ofthe top back panel 512 and bottom back panel 510 of the outer box 102 isat least equal to a length of the back panel 610 of the inner box 106,where (L_(OB-TBP)+L_(OB-BBP)=L_(IB-BKP)), and in an embodiment the sumof lengths is greater, where (L_(OB-TBP)+L_(OB-BBP)>L_(IB-BKP)), so thatthe proper fit of the inner box 106 within the outer box 102 and closureof the hinged top 104 can be realized.

Each side and dust flap of the inner box 106 is separated from theassociated and/or adjacent panel by a longitudinal fold line. The topfront panel 606 is separated from the left and right side flaps 620, 622by longitudinal fold lines 640. The top panel 602 is separated from leftand right side flaps 624, 626 by longitudinal fold lines 642. The backpanel 610 is separated from left and right side flaps 628, 630 bylongitudinal fold lines 644. The bottom panel 604 is separated from leftand right dust flaps 636, 638 by longitudinal fold lines 646. The bottomfront panel 608 is separated from left and right side flaps 632, 634 bylongitudinal fold lines 648.

FIGS. 4a and 4b are flow charts of a process for making the container inaccordance with an embodiment of the present disclosure; and FIG. 5illustrates a sequence of assembly states of the container according tothe assembly process of FIGS. 4a and 4b . As shown in FIGS. 4a and 4b ,the process includes a first step (S700) in which the inner box 106 isassembled from the inner box blank 600 by folding the left and rightside flaps 628, 630 about the longitudinal fold lines so that they aresubstantially orthogonal to the back panel 610. In step S702, the dustflaps 636, 638 of the bottom panel 604 are folded over the longitudinalfold lines 646 so that they are substantially planar with the bottompanel 604. According to an embodiment, an adhesive can be applied to thedust flaps 636, 638 so that they adhere to the bottom panel 604 whenfolded. As shown in State 1 of FIG. 5, a lower section 650 including thebottom panel 604 and the bottom front panel 608 is folded abouttransverse fold line 616 so that it is substantially orthogonal to thebottom panel 604 (S704). The consumer goods or product is then placedinto the area bounded by the left and right side flaps 628, 630 and thebottom panel 604 (S706). An upper section 652 including the top panel602 and the top front panel 606 is folded about transverse fold line 614so that the upper section 652 is substantially orthogonal to the backpanel 610 (S708, State 2). The bottom front panel 608 is folded overtransverse fold line 618 so that it is parallel with the back panel 610(S710, State 3). The top front panel 606 is folded over transverse foldline 612 so that it is parallel with the back panel 610 and planar withthe bottom front panel 608 (S712, State 4).

An adhesive can be applied to the left and right side flaps 624, 626 ofthe top panel 602. The left and right side flaps 624, 626 of the toppanel 602 are folded over longitudinal fold lines 642 and adhere to theside flaps 628, 630 of the back panel 610 (S714, State 5). An adhesivecan be applied to the side flaps 632, 634 of the bottom front panel 608and to the left and right side flaps 620, 622 of the top front panel606. The side flaps 632, 634 of the bottom front panel 608 are foldedabout longitudinal fold lines 648 and adhere to the left and right sideflaps 628, 630, respectively, of the back panel 610 (S716, State 6). Theleft and right side flaps 620, 622 of the top front panel 606 are foldedabout longitudinal fold lines 640 and adhere to the left and right sideflaps 628, 630, respectively, of the back panel 610 (S718, State 6). Itis noted that the left and right side flaps 620, 622 of the top frontpanel 606 are planar with and do not overlap the side flaps 624, 626,respectively of the top panel 602 because of the pre-cut angles of theirrespective edges.

The outer box 102 is assembled from the outer box blank 500 by foldingthe left and right side flaps 534, 536 of the bottom back panel 510about longitudinal fold lines 554 so that the left and right side flaps534, 536 are substantially orthogonal to the bottom pack panel 510(S720). The left and right dust flaps 518, 520 of bottom panel 504 arefolded over longitudinal fold lines 556 so that they are substantiallyplanar with each other and parallel with the bottom panel 504 (S722,State 7). According to an embodiment, adhesive can be applied to theleft and right dust flaps 518, 520 so that they adhere to the bottomback panel 510 when folded. A lower section 505 of the outer box 102including the bottom panel 504 and the bottom front panel 508 is foldedabout transverse fold line 544 so that the lower section 505 issubstantially orthogonal to the bottom back panel 510 (S724, State 7).The assembled inner box 106 is placed within the area of the outer box102 bounded by the left and right side flaps 534, 536 and the bottompanel 504 (S726, State 8). The bottom front panel 508 is folded overtransverse fold line 546 so that the panel is substantially parallelwith the bottom back panel 510 (S728, State 9). An adhesive can beapplied to the left and right side flaps 530, 532 of the bottom frontpanel 508. The side flaps 530, 532 are then folded about longitudinalfold lines 558 and adhere to the left and right side flaps 534, 536,respectively, of the bottom back panel 510 (S730).

An upper section 503 of the outer box 102 including the top panel 502and the top front panel 506 is folded about transverse fold line 540 sothat the upper section 503 is substantially orthogonal to the bottomback panel 510 (S732, State 9). The left and right side flaps 526, 528of the top back panel 512 are folded about longitudinal fold lines 552so that they are planar with the left and right side flaps 534, 536,respectively, of the bottom back panel 510 (S734). It is noted that theangled edges of the left and right side flaps 534, 536 of the bottomback panel 510 and the angled edges of the left and right side flaps526, 528, respectively, of the top back panel 512 are pre-cut so thatthey do not overlap and allow for opening of the hinged top 104 of theouter box 102. The top front panel 506 is folded about transverse foldline 538 so that the top front panel 506 is parallel with the bottomback panel 510 and planar with the bottom front panel 508 (S736, State16). An adhesive is applied to the left and right side flaps 522, 524 ofthe top front panel 506. The left and right side flaps 522, 524 of thetop front panel 506 are then folded about longitudinal fold lines 548and adhere to the folded left and right side flaps 526, 528,respectively of the top back panel 512 (S738, State 10). According toanother embodiment, the front flap 513 can be adhered to a back surface147 of the top front panel 506 after being folded about the transversefold line 539.

FIG. 6 shows an assembled packing 900 with an opening 908 in an innerbox 904 located within an outer box 902. The outer box has a hinged lid906 which when opened allows access to consumer items in the inner box904.

Thus, it will be appreciated by those skilled in the art that thepresent invention can be embodied in other specific forms withoutdeparting from the spirit or essential characteristics thereof. Thepresently disclosed embodiments are therefore considered in all respectsto be illustrative and not restricted. The scope of the invention isindicated by the appended claims rather than the foregoing descriptionand all changes that come within the meaning and range and equivalencethereof are intended to be embraced therein.

1. A box-in-box package comprising: a rigid outer box made of a foillined paperboard, the rigid outer box having a hinged lid configured toprovide access to an inner volume of the outer box; and a rigid innerbox made of a foil lined paperboard, the rigid inner box including, afront wall, a back wall, a top wall, a bottom wall, side walls, and asingle uncovered opening extending across the top wall and part way downthe front wall, the single uncovered opening configured to provideaccess to consumer goods in an inner volume of the inner box, the singleuncovered opening in the inner box including, a cut-out in the foillined paperboard, the single uncovered opening excluding a re-sealablelabel.
 2. The box-in-box package of claim 1, wherein the foil linedpaperboard of the outer box includes a foil layer adhered to a paperlayer and a paperboard layer, an outer surface of the paper layeradhered to an inner surface of the foil layer by a first adhesive layerand an inner surface of the paperboard layer adhered to an outer surfaceof the foil layer a second adhesive layer.
 3. The box-in-box package ofclaim 2, further comprising; a polypropylene layer on an outer surfacethe paperboard layer of the outer box.
 4. The box-in-box package ofclaim 3, wherein the polypropylene layer comprises a polypropylene film.5. The box-in-box package of claim 2, further comprising; a polyesterlayer on an outer surface of the paperboard layer of the outer box. 6.The box-in-box package of claim 5, wherein the polyester layer comprisesa metallized polyester material.
 7. The box-in-box package of claim 2,wherein the paperboard layer of the outer box comprises solid bleachedsulfate (SBS) board stock.
 8. The box-in-box package of claim 2, whereinthe first adhesive layer comprises sodium silicate.
 9. The box-in-boxpackage of claim 2, wherein consumer goods are contained in the innerbox and the paper layer of the inner box is in direct contact withconsumer goods within the inner box.
 10. The box-in-box package of claim2, wherein the inner box is formed from an inner box blank whichcomprises a front panel corresponding to the front wall, a top panelcorresponding to the top wall, a back panel corresponding to the backwall, and a bottom panel corresponding to the bottom wall.
 11. Thebox-in-box package of claim 10, wherein the inner box blank furthercomprises side panels corresponding to the side walls.
 12. Thebox-in-box package of claim 10, wherein the front panel includes a topfront panel and a bottom front panel.
 13. The box-in-box package ofclaim 2, wherein the inner box contains cigarettes in direct contactwith the paper layer of the inner box and a portion of the paper layerof the outer box in direct contact with ends of cigarettes located inthe single uncovered opening in the inner box.
 14. The box-in-boxpackage of claim 1, wherein the inner box is formed from an inner boxblank which includes a top front panel corresponding to an upper portionof the front wall separated from a top panel corresponding to the topwall by a first transverse fold line, a back panel corresponding to theback wall separated from the top panel by a second transverse fold line,a bottom panel corresponding to the bottom wall separated from the backpanel by a third transverse fold line, and a bottom front panelcorresponding to a lower portion of the front wall separated from thebottom panel by a fourth transverse fold line.
 15. The box-in-boxpackage of claim 14, wherein the inner box blank includes a first sidepanel and a second side panel corresponding to the side walls, andwherein the first side panel is separated from the back panel by a firstlongitudinal fold line, and the second side panel is separated from theback panel by a second longitudinal fold line.
 16. A box blankconfigured to form a box having a hinged lid, the box blank formed of afoil lined paperboard, the foil lined paperboard including, a paperlayer, a foil layer, and a paperboard layer, an outer surface of thepaper layer adhered to an inner surface of the foil layer and an innersurface of the paperboard layer adhered to an outer surface of the foillayer, the inner surface of the foil layer adhered to the outer surfaceof the paper layer by a first adhesive layer and the inner surface ofthe paperboard layer adhered to the outer surface of the foil layer by asecond adhesive layer, the paper layer forming an exposed inner surfaceof the box when the box blank is formed into the box.
 17. The box blankof claim 16, further comprising: a polypropylene layer on an outersurface of the paperboard layer.
 18. The box blank of claim 17, whereinthe polypropylene layer comprises a polypropylene film.
 19. The boxblank of claim 16, further comprising: a polyester layer on an outersurface of the paperboard layer.
 20. The box blank of claim 16, whereinthe paperboard layer comprises solid bleached sulfate (SBS) board stock.21. The box blank of claim 16, wherein the second adhesive layer furthercomprises sodium silicate between the foil layer and the paper layer.22. The box blank of claim 16, further comprising: fold lines configuredto form panels of a body portion and a lid portion, the body portionincluding a front panel, a bottom panel, a back panel, side panels, anddust flaps, and the lid portion including a front panel, top panel, backpanel, side panels, and dust flaps.